yp7899c1000 7800 series burner management panel - honeywell · yp7899c1000 7800 series burner...

INSTALLATION INSTRUCTIONS

66-2061-01

YP7899C1000 7800 SERIES Burner Management Panel

APPLICATIONThe 7800 SERIES Burner Management Panel is a packaged, pre-wired panel that includes the RM7800L1087 burner control, a modbus® interface, two DC2500 controls for on/off and limit control and the S7999D color touchscreen interface. The S7999D allows monitoring and control of the RM and DC controls via the modbus interface, all with user-friendly menus. On board switches, buttons and alarm lights are included for customer convenience. The burner control purge card, amplifier and flame detector are purchased separately.

This document provides installation instructions and operation information. Other applicable publications are:

— 65-0321, S7999D1048 System Display— 66-1152, RM7800L1087 Relay Module with Valve

Proving— 65-0288, S7800A1142 Keyboard Display Module 7800

SERIES— 65-0029, 7800 Series Relay Module Checkout and

Test— 65-0084, Q7800A 7800 SERIES 22-Terminals Univer-

sal Wiring Subbase— 66-2034, R78xx Amplifiers for 7800 SERIES and

R7140 Relay Modules

— 65-0089, ST7800A,C 7800 SERIES Plug-In Purge Timer

— 65-0249, S7810M Modbus Module— 60-2026, C7027, C7035, C7044, C7927 Minipeeper

UV Flame Detector— 65-0267, C7961 Dynamic Self-checking Solid State

UV Flame Detector— 60-0292, C7915 Infrared Flame Detector— 65-0277, C7962 Visible Light Flame Detector— 60-2024, C7007, C7008, C7009 flame Rod Detector— 95-8269, C7076 Adjustable Sensitivity UV Flame

Detector— 60-2398, C7012 Ultraviolet Flame Detectors— 51-52-25-127, UDC2500 Product Manual— 51-52-25-118, UDC Limit Control Model Product

Manual— 51-52-25-66, UDC Modbus RTU Serial Communica-

tions User Manual

FEATURES• Pre-wired and ready to install

• Includes the RM7800L1087 burner control with wiring subbase, S7810M modbus module, two DC2500 controls and the S7999D touchscreen display

• Monitor and control through the touchscreen interface

• Burner on/off selector switch

• Alarm lights

• Reset buttons

• Unit shutdown / Emergency stop button

• S7999D touchscreen display is modbus ready

• VPS (Valve Proving System) capability via flame safeguard control

SPECIFICATIONSElectrical Ratings120 Vac, 50/60 Hz, 10 AmpsFor individual ratings, see component literature for details.

Environmental RatingsEnclosure: NEMA 12.For individual ratings, see component literature for details.

YP7899C1000 7800 SERIES BURNER MANAGEMENT PANEL

66-2061—01 2

HumidityInstall the panel where the relative humidity never reaches the

saturation point. The relay module inside the panel is designed to operate in a maximum 85 percent relative humidity continuous, non-condensing, moisture environ-ment.

VibrationDo not install the panel where it could be subjected to vibra-

tion in excess of 0.5G continuous maximum vibration.

GeneralOverall panel size: 24in. high x 24 in. wide x 8 in. deep

(excluding door and door mounted components)Panel weight: approx. 75 poundsMounting holes are 0.44 in. typical diameter, 18 in. on center.

ApprovalsComponents are individually approved by the nationally rec-

ognized agencies. Please see component literature for details. The panel has UL 508A approval. Panel is assem-bled and wired to the UL Standards.

INSTALLATION

When Installing This Product…1. Read these instructions and the appropriate product lit-

erature carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Refer to the installation manuals and wiring diagrams provided with this panel for the embedded products.

3. Read these instructions and the appropriate product lit-erature carefully. Failure to follow them could damage the product or cause a hazardous condition.

4. Refer to the installation manuals and wiring diagrams provided with this panel for the embedded products.

5. Check the ratings given in the instructions and on the product to make sure that the product is suitable for your application.

6. Installer must be a trained, experienced combustion ser-vice technician.

7. Disconnect the power supply before beginning installa-tion to prevent electrical shock and equipment dam-age. More than one disconnect may be involved.

8. All wiring must comply with the National Electric Code (NEC) and any applicable local electrical codes, ordi-nances and regulations.

9. After installation is complete, check out product opera-tion as provided in the appropriate product installation instructions.

WARNINGFire or Explosion Hazard. Can cause severe injury, death or property damage.To prevent possible hazardous burner operation, verify safety requirements each time a controller is installed on a burner.

WIRING

WARNINGElectrical Shock Hazard. Can cause serious injury, death or equipment damage.Disconnect the power supply before beginning wiring to prevent electrical shock, equipment and control damage. More than one disconnect may be involved.

Ground ConnectionEarth ground is required for proper operation of the panel and components. The earth ground must be capable of conducting enough current to blow the fuse or breaker in the event of an internal short. Ensure the panel is bonded to a substantial earth ground. Make sure that mechanically tightened joints along the ground path are free of nonconductive coatings and protected against corrosion on mating surfaces.

Electrical Connections1. Refer to the appropriate product data sheet for details.2. Wire size and length will vary, depending on the compo-

nent. Refer to the component literature for specific wire lengths, sizes and type recommendations.

3. Wire according to specifications, following all local ordi-nances and requirements.

4. Field knockouts are required for the wiring. When drill-ing holes, take care to protect the electronics from metal pieces and debris.

IMPORTANTRun line voltage and low voltage wiring in separate conduit to avoid signal interference.

Carefully check field wiring and terminal designa-tions in this document and the associated wiring dia-gram. They are different from those of the individual components.

Panel InspectionAfter mounting and wiring, but before powering the panel, inspect all internal panel wire connections. Wires may loosen during transit. Verify that all internal wire connections are secure from the wiring subbases to the components mounted on the door and the S7999D touchscreen interface.

Final Wiring Check and Static CheckoutAll wiring shall be in accordance with the National Electric Codes (NEC) and local electrical codes.

1. Check the power supply circuit. The voltage and fre-quency must match the specification listed.

2. Check wiring terminations and routing to ensure proper connections.

3. Follow any system checkout recommendations for indi-vidual components as found in the component literature.

4. Restore power to the panel.


3 66-2061—01

CAUTIONTest each limit and interlock to ensure system operates correctly as defined in the 7800 Series “Checkout and Test” document (Form #65-0229).

WARNINGExplosion and Electrical Shock Hazard. Can cause serious injury, death or equipment damage.

1. Close all manual fuel shutoff valves before starting these tests.

2. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on.

3. Replace all limits and interlocks that are not operating properly. Do not bypass limit and interlocks.

TROUBLESHOOTING

System DiagnosticsThe S7999D touchscreen interface indicates the current fault and keeps a fault history log. The RM7800L control also has LED fault blink codes. The DC controls have various tests and status messages. Refer to the appropriate product instruction sheet for further troubleshooting information and diagnostic codes.


66-2061—01 4

FIELD WIRING

1 Carefully check field wiring and terminal designations in this document and the associated wiring diagram. They are different from those of the individual components.

2 The circuit protection incorporated into this control panel is designed to serve as supplemental protection only. It is the respon-sibility of the end user to provide appropriate protection on the service to this control panel. Refer to the National Electric Code and UL standard 1077 for more information on this subject.

Table 1. Field Wiring and Terminal Designation1.

Terminal # To Connecting Device Description

12 L1 Panel power 120Vac Power Supply, 10A Max.Provide disconnect means and overload protection as required.

2 L2 Panel neutral

GND Panel ground

4-53 Airflow Switch Combustion airflow (pressure) switch

5-63 LP Switch Fuel low pressure/temperature switch

6-73 HP Switch Fuel high pressure/temperature switch

7-83 Interlocks Fuel customer interlocks and limits, including LWCO, high-limit, etc.

10-38 Burner Control On/off burner operating control

11 Blower Motor Combustion blower motor line voltage output from burner control

154 Shutter Drive Shutter drive output connection from burner control

174 F Flame detector F lead connection from burner control

GND4 Panel ground Flame detector G lead connection from burner control

XF-25 Ignition Spark ignition transformer

18-4 Low Fire Switch Low fire switch input to burner control

20-4 High Fire Switch High fire switch input to burner control

19-2 Pilot Valve(s) Pilot fuel valve(s) connection to burner control output – 10 second interrupted pilot

21-26 Main Valve(s) Main fuel valve(s) connection to burner control output

22-43 POC Switch 1 Main fuel valve 1 proof of closure switch (pre-ignition interlock switch)

22-233 POC Switch 2 Main fuel valve 2 proof of closure switch (pre-ignition interlock switch)

25-26 Limit Relay Out High limit alarm #1 relay output, NC (DC2500 control)

26-27 Limit Relay Out High limit alarm #1 relay output, NO (DC2500 control)

28-29 Low Fire Out Customer convenience wire point - Low fire output to firing rate motor indication

30-31 High Fire Out Customer convenience wire point - High fire output to firing rate motor indication

32-33 Modulate Out Customer convenience wire point - Modulate output to firing rate motor indication

34-35 Alarm Out Customer convenience wire point - Burner control alarm output indication

2027 Temp/Press Limit + High temperature/pressure limit + input (DC2500 control)

2037 Temp/Press Limit - High temperature/pressure limit - input (DC2500 control)

2068 Mod Motor + Low fire / + connection to 4-20mA modulating motor (damper/valve)

2078 Mod Motor - Common / - connection to 4-20mA modulating motor (damper/valve)

2108 Mod Motor F High fire / F connection to 4-20mA modulating motor (damper/valve)

2087 Temp/Press Control + Temperature/pressure fire rate controller + input (DC2500 control)

2097 Temp/Press Control - Temperature/pressure fire rate controller - input (DC2500 control)

2149 COM 2 A S7999D COM 2 modbus A / Data + terminal

2159 COM 2 B S7999D COM 2 modbus B / Data - terminal

2139 COM 2 GND S7999D COM 2 Modbus C / Ground terminal


5 66-2061—01

3 Jumper all unused limits, interlocks and valve proof of closure switches.4 Refer to the appropriate flame detector product sheet for wiring size and length information. Run flame detector F and G leads

in their own conduit, independent of other power carrying leadwires. Flame detector power and shutter wires (if applicable) must be run in their own conduit as well, avoiding other electrical noise carrying wiring. The scanner wires should remain sep-arated a minimum of 2 inches from other line voltage wires in the control panel to the flame safeguard device.

5 Refer to the appropriate ignition transformer product sheet for wiring size and length information. Separate the high voltage ignition cable from other wires to avoid interference. Ignition cable to the spark electrode must be run in separate conduit (if applicable).

6 If VPS (Valve Proving System) usage is required with the RM7800 burner control, contact factory for advice regarding wiring.7 For high temperature limit, wire Type K thermocouple + input (yellow) to + terminal and - input (red) to - terminal. For pressure

limit, supply appropriate transmitter and program DC2500 controller for pressure operation. Thermocouple or transmitter wires must be run in separate conduit with other low voltage wires to avoid signal interference. DC2500 controls from the factory are set-up for temperature, but can be modified in the field for pressure operation.

8 Firing rate control output is 4-20mA. A 4-20mA firing rate/modulating actuator should be used with this panel. Run actuator low voltage field wire in separate conduit with other low voltage wires to avoid signal interference. Motor may be powered from panel T4 (L1) and T2 (L2) or separately.

9 COM 2 on the S7999D is wired in a daisy-chain fashion to the S7810M Modbus module on the RM7800L burner control and the UDC2500 controls in the panel for display on the S7999D. Customer may wire other Modbus-enabled UDC2500/3200/3500 controls in a daisy-chain fashion to the customer terminals provided for display on the S7999D. Refer to the S7999D and UDC control product manuals for further information on wiring and S7999D display set-up

10Installation, operation and maintenance shall conform with National Fire Protection Association standards, national and local codes and authorities having jurisdiction.

11For detailed device wiring information, refer to the RM7800, Q7999, S7999D1048 and DC2500 product sheets.12Spare/unused terminals are provided for customer field use.


66-2061—01 6

Fig. 1. Panel front dimensions in in. (mm) and notes.

! WARNINGElectrical Shock Hazard.Can cause serious injury,

death or equipment damage.Disconnect the power supply before beginning installationto prevent electrical shock,

equipment and controldamage. More than onepower supply disconnect

may be required.50045499-001 Rev. A

! AVERTISSEMENTRisque de choc électrique.

Peut provoquer des blessures graves, entraîner la mort ou

causer des dommages matériels.

Couper l'alimentation électrique avant de commencer l'installation pour éviter les chocs électriques, les dommages au matériel et au régulateur. Il faudra peut-être utiliser plus d'un dispositif de

coupure d'alimentation.

M34895

G

BURNER ON

LT132

B

ENERGIZEDPILOT VALVES

LT119

R

ALARMFSG

LT112

Y

PB113

FLAME

RESETSAFEGUARD

BURNER

OFF ON

SS108

W

PROVENINTERLOCKS

LT105

PUSH TO STOP

TWIST TO START

R

STOPEMERGENCY

PB101

CTLR220

CONTROLLER

Honeywell

HTL201

HIGH LIMIT

HMI306A

24 (610)

24(610)

(MAIN TERMINAL BLOCK).

INDICATES COMPONENT TERMINALS

INDICATES TERMINALS IN MAXON VALVES

INDICATES EXTERNAL WIRING

9. INSTALLATION, OPERATION AND MAINTENANCE SHALL CONFORM WITH NATIONAL FIRE PROTECTION ASSOCIATION STANDARDS, NATIONAL AND LOCAL CODES, AND

5. FIELD WIRE TO THE DETECTOR SHOULD BE #14 AWG. TYPE TW 600V INSULATED WIRE OREQUAL. WIRE MUST NOT BE IN THE SAME CONDUIT WITH POWER WIRING.

6. IGNITION CABLE TO THE SPARK ELECTRODE MUST BE RUN IN SEPARATE CONDUIT.

3. FIELD WIRING SHOWN FOR BLOCK AND BLEED VALVE ARRANGEMENT.

INDICATES TERMINALS AND WIRING IN MAXON CONTROL PANEL.

7. FIELD WIRE TO THE FIRING RATE ACTUATOR MUST BE RUN IN SEPARATE CONDUIT.

AUTHORITIES HAVING JURISDICTION.

(IF APPLICABLE)

2. JUMPER ALL UNUSED LIMITS AND INTERLOCKS.

NOTES:1. THE CIRCUIT PROTECTION INCORPORATED INTO THIS CONTROL PANEL IS DESIGNED

4. POSITION SWITCH IS REQUIRED, TYPE AND MODEL MUST BE SPECIFIED. THIS ITEMIS NOT INCLUDED WITH THE CONTROL PANEL.

TO SERVE AS SUPPLEMENTAL PROTECTION ONLY. IT IS THE RESPONSIBILITY OF THEEND USER TO PROVIDE APPROPRIATE PROTECTION ON THE SERVICE TO THIS CONTROLPANEL. REFER TO THE NATIONAL ELECTRICAL CODE AND UL STANDARD 1077 FOR MOREINFORMATION ON THIS SUBJECT.

8. THERMOCOUPLE WIRES MUST BE RUN IN SEPARATE CONDUIT.

WIRE CODE

220 VAC (NEUTRAL)

24 VAC4-20 mA SIGNAL

EXTERNAL POWER SOURCE

TYPE K THERMOCOUPLE

220 VAC (HOT)FUNCTION

16 (MTW)WHITE

16 (MTW)16 (MTW)BLUE

BROWN

YELLOW/RED

YELLOW

20 (POLYVINYL)

16 (MTW)

COLORBLACK 16 (MTW)

AWG

DRY CONTACTS YELLOW 16 (MTW)

120 VAC (HOT) 16 (MTW)RED120 VAC (NEUTRAL) 16 (MTW)WHITE

TYPE J THERMOCOUPLE WHITE/RED 20 (POLYVINYL)

VDC 16 (MTW)BLUE

F30 RESETS/DISPLAY/CONTROL BUS BELDEN 22 (AWG) TWISTED PAIR

M34896

GROUND GREEN 14 (MTW)


7 66-2061—01

Fig. 2. Equipment mounting panel dimensions in in. (mm).

M34897

21(533)

21 (533)

CUT FOR FLOOR LAYOUT

CUT FOR FLOOR LAYOUT

CU

T F

OR

FLO

OR

LAYO

UT

CU

T F

OR

FLO

OR

LAY

OU

T

FU

220

.5A

FU

201

.5A

RESET

MAINFLAMEPILOT

ALARM

POWER

HoneywellHoneywell BURNER CONTROL

FSG107

FU

302

.5A

FU10

110

A

HoneywellHoneywell BURNER CONTROLMODE

KBD114

122222222234444444556677899

101112131415161718191920212121212222232526272829303132333435XF

SPARESPARESPARESPARESPARESPARESPARE

200201204205206207GND210211211213213213214215215214GNDGNDGNDGNDGNDGNDGNDGND

-

+

203203202

-

+

209209208

XF301

CR109 CR110 CR111 CR114


66-2061—01 8

Fig. 3. Wiring diagram (part 1).

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

CUSTOMERINTERLOCKS

FIELD DEVICE

PS103A

LOW GASPRESSURE

FIELD DEVICE

PS103

COMBUSTIONAIR PRESSURE

FIELD DEVICE

PS103B

HIGH GASPRESSURE

FIELD DEVICE

4 5 6 7 8

2120

HIGH LIMITHTL201

FU10110A

PB101

EMERGENCYSTOP

21

43

9

9 2

13

14

12

11

17

15

GND

CR114FSGALARM

21813 14

NONC

16

R

LT112

X1 X2 ALARMFSG

4 22 23

XF H1 H2TRANSFORMERSPARK IGNITION

XF115

X2X1

FIELD DEVICE

PLUGSPARK

SP115

FIELD DEVICE

2

TO 120

19

TO 124

21

TO 119

4

TO 119

2

USE 16 AWG MTW WIRE120/1/60

200

201PB113

FLAMESAFEGUARD

43

RESET

SOL127

MAIN FUELVALVE

(PROOF OF CLOSURE)FIELD DEVICE

SOL130

BLOCKING FUELVALVE

(PROOF OF CLOSURE)FIELD DEVICE

to 203 to 203

CR109HIGH FIRERELAY

214,23213 14 NONC

CR110LOW FIRERELAY

21213 14 NONC

CR111MODULATERELAY

216221

13 14 NONC

SS108BURNER

OFF ONOX43

4 10

18

20

LS116

LOW FIRESWITCH

FIELD DEVICE

LS117

HIGH FIRESWITCH

FIELD DEVICE

FROM 312

207FROM 310

210FROM 311

211

MODBUS

1 2 3 4 5 6 7 8HONEYWELL

S7810M-1003-

KBD114

20

6

4

12

15

18

19

22

F

G

7 L2

5

8

9

3

10

PREIGNITIONINTERLOCK

BRN CTRLLIMITS

L1LINE VOLTAGE SUPPLY

HIGH FIRE

MODULATE

LOW FIRE SWITCH INPUT

HIGH FIRESWITCH INPUT

FLAMESENSOR

SHUTTER

FLAME SENSORGROUND

LOCKOUT/RUNNING INTERLOCKS

LINE VOLTAGECOMMON

BURNERMOTOR

PILOT VALVE/ IGNITION

MAIN FUELVALVE

ALARM

IGNITION

14

LOW FIRE

13

COMMON

17

DEMAND VALVE PROVING

16

VALVE PROVINGSWITCH

21

15 SEC INTERR. PILOT VLV, MV2

FSG107RM7800L-1087HONEYWELL

ULTRAVIOLETDETECTOR

BLU

WHTST112

FIELD DEVICE

W

LT105

PROVENINTERLOCKS

1

BLK

..

CLR

..

RE

D.

.

.. CLR .. CLR

.. BLK.. BLK

NOTE 2

NOTE 6

NOTE 1

NOTE 5

NOTE 4

GND

M34898


9 66-2061—01


119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

VENT PILOTVALVE

SOL120FIELD DEVICE

MAIN PILOTVALVE

SOL121FIELD DEVICE

BLOCKING PILOTVALVE

SOL122FIELD DEVICE

B

LT119

X1 X2 ENERGIZEDPILOT VALVES

19

19

2

FROM 115

19

FROM 1184

FROM 1182

TO 200

4

TO 200

2

21 2

2

221

21

FROM 116

21

21G

LT132

X1 X2 BURNER ON

MAIN FUELVALVE

SOL127FIELD DEVICE

118GND

MAIN FUELVENT VALVE

SOL124FIELD DEVICE

GND

BLOCKING FUELVALVE

SOL130FIELD DEVICE

118GND

NOTE 3

NOTE 3

M34899


66-2061—01 10


200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

TYPE KTHERMOCOUPLE

FROM 1354

FROM 1352

TO 219

4

TO 219

2

GND

24 FU201.5A

FROM 103

8

FROM 103

9

25

26

27

28 29

30 31

32 33

CR110

LOW FIRERELAY

9 5

CR109

HIGH FIRERELAY

12 8

CR111

MODULATERELAY

12 8

34 35CR114

FSGALARM

9 5

207

210

211

FROM 312

207

FROM 311

211

204

203TC203

FIELD DEVICE

FROM 310

210

BLK

CLR

RED

SHLD

L2/NL1/H

25 R

INPUT 1

26 +

27 -

INPUT 1

GND

20

19RELAY #1

OUTPUT

21

RELAY #1OUTPUT

8

7

9

5

4

6

ALARM #1RELAY

ALARM #1RELAY

ALARM #2RELAY

ALARM #2RELAY

16 SHLD

COMM

17 D+ (B)

18 D- (A)

COMM

HTL201

HONEYWELLHIGH LIMIT

DC2500-EE-2L0R-200-00000-00-0

YEL. . YEL. .

YEL. .YEL. .

YEL. . YEL. .

YEL. .YEL. .

M34900

DRY CONTACTS FOR CUSTOMER USE

8

9

24

25

26

27

NOTE 8


11 66-2061—01


219

220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

TYPE KTHERMOCOUPLE

FROM 2184

FROM 2182

NL

(-)

(+)

F

GND

3

8

7

HONEYWELLMODULTROL MOTOR

CM229

BLK

BLK

CLR

CLR

GND

GND

GND

2

213

209

4

4 2FU220.5A

CR111

9 1

MODULATERELAY

GND

CR109

HIGH FIRERELAY

9 5

219

208

206

TO 300

4

TO 300

2

217217

214214

TC224

FIELD DEVICE

FROM 311

211

FROM 310

210

FROM 312

207

SHLD

RED

CLR

BLK

L2/NL1/H

25 R

INPUT 1

26 +

27 -

INPUT 1

GND

19

OUTPUT 1

21

8

7

9

ALARM #1RELAY

ALARM #1RELAY

16 SHLD

COMM

17 D+ (B)

18 D- (A)

COMM

10 (+)

11 (-)

12 (+)

13 (-)

CTLR220

HONEYWELL

CONTROLLER

DC2500-CB-2A0R-200-00000-00

M34901

36

211210

207

209

38

NOTE 7

NOTE 7

NOTE 8


Automation and Control SolutionsHoneywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

customer.honeywell.com

® U.S. Registered Trademark© 2013 Honeywell International Inc.66-2061—01 M.S. 07-13Printed in United States


300

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

FROM 2354

FROM 2352

4 2

GND

FU302.5A

210

211

207

TO 113,208,227

210

TO 112,208,227

211

TO 113,208,227

207

202

202

RED

..

RE

D

..WHT

..

WH

T

.. BLK

..

BLK

212

216

1 2 3 4 5 6 7 8

CO

M

+24

VA

C

CO

M1

C

CO

M1

B

CO

M1

A

CO

M2

A

CO

M2

B

CO

M1

C

HONEYWELLS7999D1048

HMI306A

SYSTEM DISPLAY

INPUT 120 VAC

OUTPUT 24VAC

SYSTEM DISPLAY

XF301

(-)(+)

(G)

(N)(L)

POWER SUPPLY

207

207

205

GND

GND

M34902

yp7899c1000 7800 series burner management panel - honeywell · yp7899c1000 7800 series burner...

Documents